Design, manufacturing, and quality control processes are managed in an integrated structure within our organization. This approach ensures that projects are executed with speed, control, and high precision.
In addition, OTOSTECH offers a comprehensive technical infrastructure including CNC machining, press mold production, inspection fixtures, and reverse engineering. We operate as a reliable solution partner across multiple industries, particularly in aerospace, automotive, and advanced industrial applications.
Foam Block Preparation & CNC Machining
At the initial stage, EPS or PUR foam blocks are prepared based on the customer’s design. Thanks to the large machining capacity of our CNC systems, these blocks can be processed as a single piece.
With 5-axis simultaneous machining capability, seamless surface transitions are achieved. After the first machining stage, the model reaches its general form within a tolerance of ±2 mm.
The right form is the foundation of a perfect mold.
Everything begins with the right surface geometry.
Epoxy Tooling Paste Application
A high-density epoxy-based tooling paste is applied onto the machined foam surface. This layer provides both mechanical rigidity and thermal stability to the plug surface.
The material offers heat resistance in the range of 80–100°C, with low porosity and excellent machinability. The application is carried out using machine-assisted processes, followed by controlled curing.
The epoxy layer is not only about durability—it is the guarantee of precision.
CNC Finishing of Epoxy Surface
After curing, the epoxy-coated surface is re-machined using CNC. Toolpaths are programmed at micron-level precision to achieve the final geometry.
At this stage, radii, tolerances, and symmetry axes are finalized. Post-machining dimensional deviation typically remains within ±2 mm, while surface roughness is refined to Ra 0.3–0.5 µm, approaching pre-paint finish quality.
Sanding & Manual Surface Preparation
Beyond visual quality, tactile surface quality is also critical. Therefore, the plug surface undergoes fine sanding processes (P400–P1200).
The objective is to eliminate any surface imperfections that could affect optical reflections after painting. Each surface is inspected under controlled lighting conditions until it reaches A-Class Surface standards.
Primer Coat Application
The prepared surface is coated with a specialized tooling primer. This layer fills microscopic voids and ensures optimal adhesion of subsequent coatings.
After application, the surface is lightly sanded again to achieve a glass-like finish. Coating thickness and surface uniformity are carefully controlled.
Finish Coat Application
The final stage completes both the aesthetic and technical excellence of the plug. A high-gloss, UV-resistant, and heat-resistant finish coating is applied.
Color consistency and gloss uniformity are verified using a spectrophotometer. This layer ensures not only visual quality but also the smoothness required for direct transfer to the gelcoat surface during mold production.
Quality Measurement,
Digital Scanning & Reporting
The entire surface is analyzed using laser scanning and 3D measurement systems. By comparing with CAD data, a deviation map within ±2 mm tolerance is generated.
The results are delivered to the customer as a technical report—ensuring that quality is not only achieved, but also verified and documented.